Foam plug mold

                 Glued and weighted down

    Hot wire slides better on smooth surface, wrapping template edge with aluminum cut from house siding.

                     Edge wrapped for a smooth slide

                         Hot wire cut

                     Template for side cut out

        Slope 1-3/4" front to outlet and 1-1/4" sides to outlet

                             Core and support layout. Core scored halfway through.

Sides covered with packing tape, top 4 mil polyurethane film. Heating the poly took the wrinkles out after it cooled. Heating to get it to shrink and take care of wrinkles was a total guess method but it worked.

              Ready to go.....

                      West System epoxy.......

                First layer 1.5 oz cloth from
                      http://www.fiberglasssite.com/10-os-boating-cloth-50/
                 Next 3 layers 8.5 oz style 7725 cloth from
                      http://www.uscomposites.com/cloth.html
                 More layers to come after the core is bonded

Angle form for clamps